Safety Recall W86 – Rear Brake Disc – 2020 Alfa Romeo Giulia

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November 18, 2020 NHTSA CAMPAIGN NUMBER: 20V714000

Rear Brake Discs May Fracture

A rear brake disc fracture may result in a reduction of braking performance, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V714

Manufacturer Chrysler (FCA US LLC)

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 8

 

Summary

Chrysler (FCA US LLC) is recalling certain 2020 Alfa Romeo Giulia vehicles. The rear brake discs may fracture during vehicle operation.

 

Remedy

FCA US LLC will notify owners, and dealers will replace the rear brake discs and pads, free of charge. The recall began December 17, 2020. Owners may contact FCA US LLC customer service at 1-800-853-1403. FCA US LLC’s number for this recall is W86.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


Revision (1) March 2021

Dealer Service Instructions for:

Safety Recall W86 / NHTSA 20V-714 Rear Brake Discs

 

NOTE: Additional information added to “Parts Return” section on Page 3.

 

Remedy Available

2020 (GA) Alfa Romeo Giulia

 

NOTE:  This recall applies only to the above vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle  inventory.  Federal law requires you to complete this recall service on these  vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The rear brake discs on about 8 of the above vehicles may fracture. A rear brake disc fracture during vehicle operation may result in reduced braking performance, which can cause a vehicle crash without prior warning.

 

Repair

Replace the rear brake discs and brake pads.

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

 

Parts Information

Part Number Qty. Description
68416484AA 1 Rear brake pad and disc kit (4 pads and 2 discs)
68300207AA 4 Parking brake caliper fastening screw (MSQ 4)
06106188AA 2 Cable tie (MSQ 10)

 

Parts Return

Using DHL parcel service, provide the Brembo customer number 958130361 to send back the recalled brake discs so that shipping can be charged directly to the supplier without cost to the dealership. Use the packaging from the NEW brake discs to return the recalled brake discs to Brembo.

 

Send only the removed brake discs, attaching a pro forma invoice containing details of the components being returned and the mileage at which the operation was carried out.

 

The pro forma invoice must contain the following words:

(For repair free of charge, value for customs purposes only) INCOTERMS 2010 (ICC): DAP CURNO, ITALY

 

Send the recalled brake discs to the following address:

Brembo S.p.A.
Via Brembo, 25
24035 Curno (Bergamo) – Italy
To the attention of Mr. Claudio Trinceri

 

IMPORTANT: Failure to return the recalled brake discs will result in the cancellation of the refund claim.

 

Special Tools

The following special tools are required to perform this repair:

  • NPN
wiTECH MicroPod II
  • NPN
Laptop Computer
  • NPN
wiTECH Software
  • NPN
Dial Indicator for measuring brake disc eccentricity

 

Service Procedure

 

  1. Position the vehicle on a suitable lift.

 

  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts.  Set the battery charger timer (if so equipped) to continuous charge.

 

  1. Connect the wiTECH micro pod II to the vehicle data link connector.

 

  1. Place the ignition in the “RUN” position.

 

  1. Open the wiTECH 2.0 website.

 

  1. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen.  Click “Accept”.

 

  1. From the “Vehicle Selection” screen, select the appropriate vehicle.

 

  1. From the “Action Items” screen, select the “Topology” tab.

 

  1. Select the “ABS” Icon.

 

  1. From the “ABS” screen, select the “Miscellaneous Functions” menu and start the “Brembo® information CCM service reset” procedure for rear disc replacement.

 

Electrical System Disconnection:

 

  1. Raise all electrical windows to the upper stop position.

 

NOTE:  Make sure ALL the windows are closed fully.  Disconnecting the battery when the windows are in a position other than the upper end stop will entail the need to run the window end stop learning procedure.

 

  1. Open the luggage compartment lid and support it so it will not close.

 

CAUTION: While the battery is disconnected, make sure the luggage compartment lid does not close again, as it will not be possible to reopen it.

 

  1. To be able to reopen the luggage compartment lid, even if it accidentally closes with the battery disconnected, before disconnecting the battery it is necessary to unscrew the cap (1b), release the pull cord hooked onto it and leave it hanging out of the luggage compartment. Then, by working on the pull cord, an emergency luggage compartment lid lock release can  be obtained. The pull cord operates on the lever (1a) inside (Figure 1).

 

  1. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device and battery charger from the vehicle.

 

  1. The vehicle must remain powered down for at least 1 minute before taking further action.

 

  1. Working on the right side of the luggage compartment, turn the retainers (1a) counterclockwise to the end of their travel to release them, then remove the cover (1b) releasing the retainers in the areas (1c) (Figure 2).

 

  1. Press the release button (1a) and disconnect the negative cable (1b) from the battery post (1c) (Figure 3).

 

  1. Move the terminal out of the way and isolate it (1b) (Figure 3).

 

  1. If equipped with an Intelligent Battery Sensor (IBS), disconnect the wire harness connector (2a) from the IBS (1c) (Figure 4).

 

Rear Brake Pads and Disc Removal for Both Sides of Vehicle:

 

WARNING: The presence of carbon fiber submerged in a ceramic matrix can produce dust (carbon) that is deposited in the disc pads and surfaces. This dust can cause skin irritation, redness and burns. The technician must use personal protective equipment to protect their health: gloves and mask.

 

  1. Remove both rear tire and wheel assemblies.

 

  1. Disconnect the electrical harness connector (1) to the electric parking brake gear motor (Figure 5).

 

  1. Remove and DISCARD the mounting bolts (2a) and remove the electric parking brake caliper (2b) (Figure 5).

 

  1. Disconnect the brake pad wear indicator electric harness connection (1) (Figure 6).

 

  1. Cut the tie strap and release the electrical harness from the support bracket (2) (Figure 6).

 

  1. Using a suitable punch, retract and remove the pad retaining pins (3) (Figure 6).

 

  1. Open the cap on the brake fluid reservoir and check the level.

 

NOTE: The piston retraction operations described here below increase the brake fluid level in the reservoir. Make sure the fluid level does not cause leakage.

 

  1. Retract the pistons from the brake caliper using a retractor or other suitable tool pressing on the worn pads.

 

NOTE: Piston retraction must be such so allow extracting the worn pads and then inserting the new ones.

 

  1. Remove the mounting bolts (1a) and remove the brake caliper (1b) complete with pads, without disconnecting the brake hose (Figure 7).

 

CAUTION: Securely support the brake caliper so it does not put stress on the brake hose.

 

  1. Remove the outer brake pad (1) (Figure 8).

 

  1. Remove the inner brake pad (1) (Figure 9).

 

NOTE: If the pads are stuck to the pistons, use a spatula or screwdriver and then extract the pads from the caliper. Be careful not to damage the pistons and the dust boots.

 

  1. Remove and DISCARD the brake caliper retaining clip (1) (Figure 10).

 

NOTE: The spring must always be replaced.

 

  1. Carefully clean the pad seat area using suitable materials and products (for example, a moist cloth).

 

CAUTION: Do not use products which could damage rubber parts, such as thinner, nitro thinner, petrol, etc.

 

  1. Check that there is no damage to the pistons or the dust boots.

 

  1. Remove the mounting bolts (1a) and remove the rear brake disc (1b) (Figure 11).

 

NOTE: Use the packaging from the NEW brake discs to return the recalled brake discs to Brembo. Failure to return the recalled brake discs will result in the cancellation of the refund claim.

 

Rear Brake Disc and Pads Installation for Both Sides of Vehicle:

 

  1. Place the NEW rear brake disc (1a) onto the wheel hub and tighten the M10 bolt (1b) to 7 N·m (62 In. Lbs.) (Figure 12).

 

NOTE: After install the CCM discs, measure the eccentricity of the disc-wheel hub assembly with a dial indicator. An eccentricity of more than 0.10 mm is not  acceptable. 

 

NOTE: If the eccentricity is greater than 0.10 mm, rotate the disc to another position (there are 5 available positions) to achieve the smallest eccentricity possible. 

 

NOTE: The eccentricity must be measured 10 mm from the disc’s outer edge, on the braking side. The correct eccentricity value is vital for stabilizing braking. If the eccentricity values are too high, it will result in abnormal wear and strong vibrations.

 

  1. Install some “MOLYKOTE Cu7439 Plus” grease to the brake pad sliding shoulders and a NEW brake caliper retaining spring in its housing (Figure 13).

 

  1. Install the NEW inner brake pad (2) in its housing, complete with wear sensor (2) (Figure 14).

 

NOTE: The arrow printed on the brake pad must be oriented in the direction of rotation of the disc when travelling forwards.

 

  1. Install the NEW outer brake pad (1) in its housing (Figure 15).

 

NOTE: The arrow printed on the brake pad must be oriented in the direction of rotation of the disc when travelling forwards.

 

  1. Install the brake pad retaining pins (1) (Figure 16).

 

  1. Position the brake caliper (1a) in its housing and set the brake pad retaining pins (1b) (Figure 17).

 

  1. Install the brake caliper M12 mounting bolts (2) and tighten the bolts to 105 N·m (77 Ft. Lbs.) (Figure 17).

 

  1. Connect the electrical harness connector to the pad wear sensor (3a), secure it to the bracket with a NEW cable tie (3b) (Figure 17).

 

  1. Pump brake pedal several times to set pads to caliper and brake rotor.

 

  1. Check that the brake fluid in the reservoir is at the maximum level, otherwise top off using the recommended fluid.

 

  1. Securely tighten the brake fluid reservoir cap on the brake fluid reservoir.

 

NOTE: The fluid in the reservoir should not exceed the MAX notch.

 

  1. Position the electric parking brake caliper (1a) in its housing and tighten the NEW M10 mounting bolts (1b) to 30 N·m + 45 degrees (22 Ft. Lbs. + 45 degrees) (Figure 18).

 

  1. Connect the electrical connection of the gear motor (2) (Figure 18).

 

  1. Position the rear wheel and tire assembly to the wheel hub and secure it tightening the M14 stud bolts to 120 N·m (89 Ft. Lbs.) (Figure 18).

 

Electrical System Connection:

 

  1. Connect the battery negative cable (1b) onto the post (1c) (Figure 19).

 

  1. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector (Figure 20).

 

  1. Position the battery cover (1b) while engaging the retainers (1c), then turn the retainers (1a) clockwise to the end of their travel to secure them (Figure 21).

 

  1. Close the luggage compartment lid.

 

Electrical Systems Reset:

 

  1. Initializing the steering is required. This will be indicated by a warning light on the IPC illuminating. Start the engine, turn the steering wheel from one lock to the other and turn it back into the center position.

 

  1. Check that the time/day etc. are correct.

 

  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts.  Set the battery charger timer (if so equipped) to continuous charge.

 

  1. Connect the wiTECH micro pod II to the vehicle data link connector.

 

  1. Place the ignition in the “RUN” position.

 

  1. Open the wiTECH 2.0 website.

 

  1. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen.  Click “Accept”.

 

  1. From the “Vehicle Selection” screen, select the appropriate vehicle.

 

  1. From the “Action Items” screen, select the “Topology” tab.

 

  1. Select the “ABS” Icon.

 

  1. From the “ABS” screen, select the “Miscellaneous Functions” menu and go to the “Electric Park Brake (EPB)” then perform the “ASSEMBLY CHECK” procedure.

 

  1. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device and battery charger from the vehicle.

 

  1. Remove the vehicle from the lift and return to the customer or inventory.

 


 


1 Affected Product

Vehicle

MAKE MODEL YEAR
ALFA ROMEO GIULIA 2020

 


12 Associated Documents

Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (GA) Alfa Romeo Giulia vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.

RCMN-20V714-3982.pdf 100.588KB

RCMN-20V714-3982

 


Recall Quarterly Report #1, 2020-4

RCLQRT-20V714-8485.PDF 211.128KB

RCLQRT-20V714-8485

 


Remedy Instructions and TSB – Rear Brake Discs

RCRIT-20V714-8398.pdf 1535.627KB

RCRIT-20V714-8398

 


Owner Notification Letter(Part 577)

RCONL-20V714-9430.pdf 514.792KB

RCONL-20V714-9430

 


Remedy Instructions and TSB

RCRIT-20V714-5277.pdf 1455.523KB

RCRIT-20V714-5277

 


Recall Quarterly Report #2, 2021-1

RCLQRT-20V714-1145.PDF 211.23KB

RCLQRT-20V714-1145

 


ISSUED Renotification Notice

RCRN-20V714-9961.pdf 138.314KB

RCRN-20V714-9961

 


Recall Acknowledgement

RCAK-20V714-5926.pdf 244.756KB

RCAK-20V714-5926

 


Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (GA) Alfa Romeo Giulia vehicles equipped with Carbon Ceramic Material (CCM) rear brake discs.

RCMN-20V714-5014.pdf 97.249KB

RCMN-20V714-5014

 


Defect Notice 573 Report

RCLRPT-20V714-6615.PDF 213.853KB

RCLRPT-20V714-6615

 


Recall Quarterly Report #3, 2021-2

RCLQRT-20V714-5838.PDF 211.311KB

RCLQRT-20V714-5838

 


Recall Quarterly Report #4, 2021-3

RCLQRT-20V714-4232.PDF 211.414KB

RCLQRT-20V714-4232

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V714&docType=RCL

 


 

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